Method for splicing webs

ABSTRACT

THE INVENTION IS DIRECTED TO A METHOD FOR SPLICING RELATIVELY THICK, CARDBOARD WEBS WHEREIN A SIMPLE OVERLAP SPLICE IS FIRST EFFECTED WHEREUPON THE SPLICED WEB IS DIRECTED THROUGH ABRADING MEANS TO THEREBY REDUCE THE DOUBLE WEB THICKNESS OF THE SPLICE TO SUBSTANTIALLY NORMAL WEB THICKNESS.

Filed Apr l 8 l 9 68 Ap 197l B. PASQUINELLI METHOD FOR SPLICING WEBS 2 Sheets-Sheet 2 Filed April 8, 1968 INVENTOR BRUNO B. PASQUlNELLI BY #mwmaL ATTORNEYSA" United States Patent O 3,575,759 METHOD FOR SPLICING WEBS Bruno B. Pasquinelli, Evergreen Park, Ili., assignor to Miehle-Goss-Dexter, incorporated, Chicago, Ill. Filed Apr. 8, 1968, Ser. No. 719,437 Int. Cl. Bh 19/18 U.S. Cl. 156-159 4 Claims ABSTRACT OF THE DISCLOSURE The invention is directed to a method for splicing relatively thick, cardboard webs wherein a simple overlap splice is first effected whereupon the spliced web is directed through abrading means to thereby reduce the double web thickness of the splice to substantially normal web thickness.

The invention pertains to web handling machines. It is directed more specifically to an improved method and apparatus for splicing -web material, particularly cardboard or the like relatively thick material while said material is being fed at a Constant speed to a web processing machine.

In the operation of web processing machines such asrotary printing presses and rotary die cutting and creasing presses, it is highly desirable, once the machines have been set in operation, to keep them running at a constant speed for as long as possible and preferably until a given job is completed. This is important because each time such press is tripped, slowed-down or stopped, a finite period of time is required before the various mechanisms of the press regain a state of equilibrium or balance at the normal running speed. Until this balanced state is achieved, the products produced are not generally of an acceptable quality and they are accordingly disposed of as Waste. Therefore, any means whereby frequent changes in the normal operation of these presses can be avoided constitutes a significant advantage to the operators.

One of the primary and heretofore unavoidable reasons for interrupting the normal operation of cardboard processing machines at frequent intervals has been due to the splicing function. Obviously, it would be advantageous to employ flying pasters for this purpose, such as are commonly used in conjunction with newspaper presses and which would be capable of eifecting splces at normal press speed. This has been impracticable heretofore, however, because such devices form an over-lap splice and the resultant double thickness of cardboard at the splice would far exceed the permissible limits of the processing machine. Consequently, it would be necessary to trip the units to avoid smashing the coacting elements as the splice passed through. Not only would this require special detectors and timing means for coordinating the tripping motion with the movement of the splice, but such tripping of the units also would disturb the balanced Condition of the press. Therefore, any advantage gained by effecting the splice at press speed would be offset by the tripping action and the resultant amount of Waste incurred.

It has been the general practice therefore to employ special devices for making butt-joint splces in cardboard webs to eliminate the need for tripping the press units. The latter devices have been used quite extensively but they do not eliminate the problern. To make. a butt splice it is necessary that the web be stopped, at least momentarily. Although some of the splicers incorporate web reservoir means so that the press proper does not have to be stopped completely while the splice is made, nevertheless they do require that ,the speed of the press be substantially reduced. Consequently, this disturbs the normal running balance or equilibrium of the press with the 3,575,759 Patented Apr. 20, 1971 result that a substantial amount of Waste is incurred until the press returns to normal operation.

The present invention completely overcomes the disadvantages of the known splicing systems and contemplates a method and apparatus which will enable splces to be made in cardboard webs without in any way disturbing the normal operation of the press. In accordance with the invention an overlap splice may be effected by means of a conventional flying paster de-vice after which the excess thickness of the web in the area of the splice is reduced to substantially normal web thickness before it enters the processing machine. Moreover, special means may be provided for treating the Web after the excess thickness has been removed so that in many instances, not even the spliced area of the Web need be wasted.

It is a primary Object of this invention, therefore, to provide an improved method and apparatus for splicing relatively thick cardboard webs which can be accomplished while the web processing machine continues to operate at a normal speed.

Another Object of the invention is to provide a splicing system for cardboard webs which includes the step of forming an overlap splice by means of a conventional high speed flying paster and which includes the provision of means for reducing the thickness of the web in the area of the splice before the latter enters the. processing machine.

A further Object resides in the provision of means for cleaning and treating the web in the area of the splice to thereby preclude problems which may be caused by loose fibers or particles clinging to the web.

Other objects and advantages will become apparent from the following description and the accompanyng drawings which illustrate a preferred embodiment of the invention and wherein;

FIG. 1 is a relatively schematic side elevational view of a web feeding and splicing apparatus, incorporating the novel features of this invention;

FIG. 2 is an enlarged sectional View illlustrating how the leading edge of a new roll of web material is spliced to the web being fed from an expiring roll;

FIG. 3 is an enlarged sectional view illustrating the. appearance of the completed splice and how the lead edge of the new roll preferably is prepared prior to the splicing operation; and,

FIG. 4 is an enlarged sectional view illustrating how the excess thickness of the web is removed in the area of the splice prior to entering the processing machine.

With reference now to the drawings, the invention is disclosed in conjunction with a web feeding mechanism which includes a conventional turnover supply roll stand indicated by the reference number 10 which is adapted to provide a support for two rolls of web material to be processed. One r0ll.11 is shown as located in the feeding position and the web 12 which is being withdrawn therefrom, is directed over a series of guide rollers 13, 14, 15, 16 and 17 to the rollers 18, 19 and 20 of a conventional infeed unit which serves to withdraw the web from the roll 11 and feed it at the proper rate into a converting machine such as a rotary printing or die cutting and creasing press.

The other roll 241 represents a fresh roll of the web material which has pre viously *been prepared for the splicing operation and it is shown as being located in the standby position preparatory to being spliced to the web 12 as the roll 11 is about to expire. Although the respective associated mec'hanisms have not been shown, since they form no part of the present invention, it will be understood that the roll stand 10 includes suitable brake means for controlling the speed of the rolls 11 and 21 whereby to maintain the desired tension in the web as it is being withdrawn. Also, suitable drive means are provided for accelerating each new roll, such as the roll 21, up to the speed of the web 12 prior to etfecting a splice and, of course, means are provided for rotating the rolls 11 and 21 bodily about the axis of the main supporting shafi: 22 of the roll stand between the feeding and standby positions.

As the web 12 travels from the roll 11 to the guide roller 13 it normally is spaced a short distance from the periphery of the new roll 21 in the standby position. However, when a splice is made, the web 12 is pressed against the periphery of the new roll, which at that time has been accelerated up to the linear speed of the web 12, by means of a presser roll 23 that is located below the path of the web and adjacent the new roll 21.

The presser roll is adapted to be moved between a retracted position wherein it is spaced a substantial distance from the web 12, a ready position wherein it supports the we'b 12 closely adjacent but not in contact with the new roll 21, and a splice position wherein it presses the web 12 into ir-timate contact with the surface of the new roll 21. For this reason it is journalled for rotation in spaced arms 24 that are pivotally mounted on a cross shaft 26 and these arms in turn are adapted to be moved between the respective positions by means such as the air cylinders 27 which are pivotally connected to the arms as at 28 and to a frame member as at 29.

The arms 24 also provide support for a knife 30 which extends transversely across the path of the web and which is adapted to sever the trailing portion of the web 12 upon movement of the presser roll 23 to the splice position.

The apparatus described thus far is essentially the same as that commonly used for feeding and splicing webs being fed to newspaper presses. In this standard procedure, the new roll 21 of newspaper stock is made ready for the splicing operation when it is first installed on the roll stand so that the splice can be elfected at the required time without interrupting the operation of the press. The make-ready essentially consists of taping the lead edge of the new web roll in position so that it will not unwind when the new roll is accelerated up to web speed and applying a band of adhesive on the outer surface of the new web roll adjacent the leading edge thereof so that when the expiring web is pressed against the periphery of the new web roll, the leading edge thereof will break away from the roll and adhere to the web. Simultaneously with the pressing of the web against the new web roll, the knife 30 severs the trailing portion of the expiring roll so that the splice is completed and the web will commence to be fed from the new roll.

This procedure obviously produces an overlap splice, but because newspaper stock is relatively thin, ranging in thickness from about .003" to .004", the double thickness of the splice can be accommodated by the press units. Cardboard, on the other hand, ranges between about .012" to .O40" in thickness, and therefore, the double thickness of a conventional overlap splice would far exceed the limits of any Converting machine and would necessitate tripping of the working members.

Accordingly, the present invention contemplates an improved method of splicing cardboard which utilizes the known mechanisms but which introduces a novel variation in the make-ready procedure for the new roll and the addition of means for conditioning the web after a splice has been made.

With reference now to FIGS. 2 and 3 a preferred method of the invention -contemplates preparing the new roll, when it is first mounted in the roll stand, by beveling or chamfering the leading edge 31 thereof so that it will taper from substantially a knife edge as at 32, to the full web thickness as at 33. The length of the taper may vary with relation to the thickness of the web, but it should not be 4 substantially less than about two inches so as to provide adequate surface area for an effective splice.

Upon completing the preparation of the lead edge of the new web roll, it is attached by suitable tape or other adhesive to the surface of the roll .so that it will not unwind when the new roll is accelerated up to the speed of the running web and the beveled surface 34 is coated with an adhesive so that it will adhere to the running web when the latter is pressed into contact with the periphery of the new roll by the presser roll 23.

It will be apparent that when initially mounted on the ro l stand and while it is being made ready, the new roll will occupy the position of roll 11 in FIG. 1. At this time the web will be feeding from a roll in the position of roll 21 in FIG. 1. After preparation of the new roll is completed, the roll stand will be actuated to move the new roll to the stand by position of roll 21 and the latter roll will be moved to the feeding position of roll 11.

When the roll 11 reaches a predetermined minimum diameter, the new roll 21 will be accelerated up to the speed of the running web 12 by any conventional means commonly used for this purpose. Following this action the air cylinders 27 will be activated to move the presser roll to the ready position wherein it supports the web 12 closely adjacent, but slightly spaced from the new roll 21. Thereafter, when the expiring roll 11 has reached a further predetermined minimum diameter, the air cylinder will be activated to move the presser roll 23 to the splice position wherein the expiring web 12 will be pressed against the new roll, as illustrated in FIG. 2, and the adhesive on the tapered surface 34 of the new roll will cause the leading edge thereof to adhere to and follow the expiring web 12. At the same time or immediately thereafter the knife 30 will cut off the trailing portion of web 12.

In order to assure that the splice is sufliciently secure as to carry the new web through the following splice processing stations, the web is directed through a nip formed by the idler roller 13 and a pressure roller 36 so that the leading edge of the new web roll will be positively secured to the expiring web 12. The roller 36 preferably comprises a cylinder having a continuous surface and it is journalled for rotation in adjustable eccentric bearing housings 37 or equivalent structure which will provide for adjustment of said roller 36 relative to the idler roller 13 in accordance with the thickness of the web material. The roller 36 may be driven constantly at the same speed as the roller 13 through intermeshing gears on the respective roller shafts, but such drive preferably would include clutch means so that the roller 36 could be disengaged from the drive and remain idle except when a splice is made. The bearing housings 37 also are connected to trip means, not shown, but which are effective to rotate the bearing housings so that the roller 36 can be maintained in a tripped position, spaced from the roller 13, except when a splice is made.

The trip mechanism preferably is adapted to be actuated so that it will move the roller 36 to its operatve position upon actuation of the presser roll 23 and then return said roller to its inoperative, tripped position immediately after the splice has passed.

After passing through the nip of the rollers 13 and 36, the splice appears as illustrated more clearly in FIG. 3. It will be noted that the top surface of the web is substantially continuous, being interrupted only by a relatively fine line along the knife edge 32 of the new web roll. The old web 12, on the other hand is deflected in a plane parallel to the tapered surface 34 of the new web from the point 32 to the point 33. Accordingly, in this area of the splice the thickness thereof progressively increases from normal web thickness to substantially double web thickness at the point 33 and this double thickness continues for the length of the remaining tail portion 35 of the old web. It is essential, therefore, that the excess material in the area of the splice and the tail portion 35 of the old web, be removed before the splice enters the converting machine.

Accordingly, upon passing through the nip of the rollers 13 and 36, the web is directed through an abrading station which essentially consists of the dler roller 14 and a coacting cylinder 38 which is arranged immediately below and parallel to the roller 14. The cylinder 38 is adapted to be driven in a direction opposite to the movement of the web, as indicated by the arrows in FIGS. 1 and 4 and it has a continuous periphe'al surface provided with abrading means, such as, for example, the abrasive granules 39 illustrated in FIG. 4. The abrasive granules are adapted to remove the excess material in the area of the splice as well as the tail portion 35 of the severed Web as the splice passes through the nip of said roller and cylinder. The cylinder 38 is journalled for rotation in eccentric bearing housings 41 which are adjustable so that the surface of the cylinder can be spaced from the dler roller 14 in accordance with the thickness of the web material to be processed and the eccentric housings are also connected to suitable trip means, not shown, so that they can be actuated to move the cylinder between an operative position, as illustrated, and an inoperative position wherein it is spaced a substantial distance from the roller 14.

Under normal circumstances, the cylinder 38, in its operative position, would be spaced from the dler roller 14 a distance slightly less than the thickness of the web. Accordingly, as the splice passes through the nip of said rollers, as illustrated in FIG. 4, the abrading cylinder 38 will grind away the excess thickness of the web material so that the area of the splice will be substantially the same thickness as the remainder of the web.

Moreover, it will be seen that as the splice passes between the roller 14 and abrading cylinder 38, the said cylinder will remove that material constituting a portion of the initial or original web 12. Consequently as it reaches a point adjacent the end 33 of the tapered portion 34 of the new web, it Will cut through and thereby sever the loose tail portion 35 of the old web so that it Will not be carried through the Converting machine.

If desired, vacuum means as represented by the chamber 43 may be positioned adjacent the entry side of the nip to entrap and remove the dust particles created by the abrading cylinder 38.

In many circumstances, the web may be directed from the abrading station directly into the infeed rollers and thence into the Converting machine. On the other hand, if the web is to be fed into a printing press it is desirable that all dust and loose particles le removed therefrom so that such particles will not affect the printing or contaminate the ink. In such case, upon leaving the cylinder 38, the web is directed through a vacuum cleaning station which essentially consists of a chamber 44 having rotary brushes 45 mounted theren on each side of the web and which remove the dust and loose particles from the web.

With the apparatus arranged as shown in FIG. l it will be noted that the new web is spliced to the top surface of the expiring web. Therefore this surface, which is adapted to receive subsequent processing, is not marred by the abrading means and if the lead edge of the new roll has been properly prepared, and carefully beveled the splice will be virtually undetectable and the product formed or printed on the splice will, in many instances, be acceptable.

If the web is to be perfected, however, i.e. printed on both sides, the rough, abraded side of the splice would be objectionable and the product formed or printed thereon would have to be discarded. Accordingly, the invention contemplates the provision of a web reconditioning unit 46 consisting of a chamber 47 which contains spray nozzles 48 or the like for spraying a surface coating material onto the abraded portion of the web and which nozzles can be on either one or both sides of the web. After passing the spray nozzles, the web is then directed between finshing rollers 49 which serve to distribute and smooth out the coating material so as to provide a uniform, smooth coated surface over the abraded area, whereupon the web is directed through a drying unit 51 to dry the coating material before it enters the infeed unit.

Under some circumstances and depending upon the material in the web, it may be desirable to perform the abrading function in two or more steps. In such case the abrading cylinder 38 Would be provided with a relatively coarse granular coating and it would serve to remove the major portion of the excess splice material. A second abrading cylinder 52 would then be positioned immediately after cylinder 38 and adjacent roller 14. The second abrading cylinder Would be similarly mounted and actuated but it preferably would 'be coated with finer granules so as to provide a smoother finish on the web.

It will also be noted that in the arrangement thus far described, the new web is spliced to the top surface of the expiring web and the excess material is removed from the 'bottom thereof. In some instances it may be desirable or imperative that the new roll be spliced to the bottom surface of the expiring web. In such case the direction of the web could be changed by employing additional guide rollers so that the foregoing abrading rollers Would operate on the top surface thereof. However, another abrading cylinder 53 could be provided adjacent the dler roller 15 to take care of such situations. Under such circumstances the abrading cylinders 38 and 52 would be tripped to an inoperative position.

The provision of an additional abrading roller 53 has the further advantage in that it can be used in conjunction with the preceding abrading cylinders whereby the make-ready procedure of the new rolls could be simplified. If, for example, it is impracticable to bevel the leading edge of the new roll as illustrated in FIG. 2, it would still be possible to utilize an over-lap splice without incurring the above mentioned problems. 'In such event, a simple over-lap splice could be made which would first be passed through the nip of the roller 14 and abrading cylinder 38 which latter cylinder would be spaced from the roller 14 so that it would remove substantially only one-half of *the excess over-l-ap thickness from one side of the web. Thereafter, the web would pass through the nip formed by the abrading cylinder 53 and the idler roller 15 which would be set so as to remove the remaining excess thickness of the splice from the other side of the web. Accordingly, the splice would be reduced to normal web thickness in two successive steps, one on each side thereof and could then pass through the press without necessitating tripping of the units.

In a splicing system of this type, it will be appreciated that suitable trip mechanisms are incorporated theren for moving the various rollers, cylinders and web reconditioning members between operative and inoperative positions relative to the web. For convenience purposes, the mechanisms for effecting such tripping motions have not been shown because they are not critical to the invention and any of the well known conventional arrangements may be employed. In other words, any suitable mechanical, hydraulic, pneumatic or electrical device may be employed to impart the necessary angular motion to the eccentric bearing housings 37-41 etc. to thereby shift the cylinders between operative and inoperative positions. Furthermore, these devices would be responsive to a splice detector or possibly the movement of the presser roll 23 to the splice position, so that they would be moved to and from their operative positions sequentially and in timed relation with the passing of the splice.

The said tripping devices also would be connected to the bearing housings by means including, for example, an .adjustable turnbuckle or worm 'and worm gear means whereby the housings can be adjusted relative t-o the tripmechanism to position the abrading cylinders, etc. relative to the coactng guide rollers in accordance with the thickness of the cardboard to be processed.

All of the ab'ading rollers Would be rotated in a direction opposite to the direction of the web travel and they may be actuated from the main drive through suitable gearing and clutch means or they may be driven by independent drive means which Would be energized only when a splice is to be made.

It should also be understood that whereas we have referred to abrading cylinders herein and more specifically to cylinders having granules applied to or coated on their surface, this is not to be regarded as a limitation. Actually any suitable cutting, shaving, grinding or sanding means may be utilized for this purpose, such as a mlling cutter, or a grinding cylinder for example, and therefore the term abrading means or abrading cylinder as used in the foregoing description and in the appended claims is intended to encompass any such means which may be utilized to cut, shave, grind, sand or otherwise remove the excess thickness of the web.

Having thus described a preferred embodiment and method of inventon;

What is claimed is:

1. The method of splicing a new roll of relatively thick web material to a web of like material traveling at a constant speed from an expiring roll to a Converting machne comprising, the steps of beveling the lead edge of the new roll While at rest to provide a tapered surface for contact with the traveling web, applying adhesive along the tapered lead edge of the new roll also while it is at rest, then accelerating the new roll up to the speed of the traveling web, pressing the traveling web against the periphery of the new roll whereby the adhesive coated leading end of the new roll adhe'es to and travels With the traveling web and forms an over-lap splice of substantially double web thickness, severing the trailing portion of the traveling web after the splice is eflfected and while the traveling web continues to advance at a constant speed, and passing the traveling Web and the overlap splice at the same constant speed through an abrading station to remove the excess thickness of web material in the area of the splice.

2. The method as set forth in claim 1, including the additional step of passing said web through a cleaning station after it has passed through the abrading station to remove dust and lint from the abraded splice before it enters the Converting machine.

3. The method as set forth in claim 1, including the steps of applying coating material to the abraded surface of the web, smoothing and distributing the coating material unformly over the abraded area, and then drying the coating material before it enters rthe Converting machine.

4. The method as set forth in claim 1 including the step of passing the web through a second abrading station to thereby smooth the rough, abraded surface of the splice after it leaves the first abrading station.

References Cited UNITED STATES PATENTS 3,489,624 '1/1970 Catzen 156-159 2,160,526 5/1939 Tollison 156-157 2,724,426 11/1955 Bell et al. 156-159 3,125,477 3/1964 Laliberte 156-154 CARL D. QUARFORTH, Primary Examiner B. H. HUNT, Assistant Examiner U.S. Cl. X.R. '156-153, 157 

